Process and apparatus for making electrical connecters



Dec. 15, 1931. L E. POQLE 1,836,500

PROCESS AND APPARATUS FOR MAKING ELECTRICAL CONNECTERS Filed Feb. l5, 1929 5 Sheets-Sheet l mmmmzxyd Deu 15, 1931. A L, E. PQOLE' 1,836,500

PROCESS AND APPARATUS FORMAKING ELECTRICAL CONNECTERS PROCESS L. E. POOLE 1,836,500

AND APPARATUS FOR MAKING ELECTRICAL CONNECTERS 'Filedl Feb. 15, 1929 54 54 40 ab .sa 44 the manufacture of flexible connectors for4 Patented Dec'. l5, 1931 UNITED STATES "PATENT lol-Flcs LORA E. IPOOL, OF ANDERSON, INDIANA, ASSIGNOR DELOO-REMY CORPORATION,

OF ANDERSON, INDIANA, A CORPORATION F DELAWARE PROCESS AND APPARATUS FOR MAKING ELEUIRICAL CONNECTERS Application led February 15, 1929. Serial No. 340,077. A

This invention relates to the manufacture of flexible connectors, and in particular to brushes.

It is among the objects of this invention to reduce the cost of makingflexible connectors,

sometimes called pig tails, by reducing the amount of labor and the time of making. This is accomplished by providing means for feeding a cable which is to be used in the manufacture of the leads to a station where kthe pre-formed connector ris moved to a position to embrace the cable, then feeding the i cable to a station where the clip of the connector is Acrimped to the cable and finally feeding the cable and the crimped clip to a station where the cable is severed. From this it may readily be seen that the cost of production may be reduced as all that is necessary for the operator to do is to insert a pre-formed clip in the pre-assembly position, from here on all of these steps are pre-formed by a machine.

Further objects and advantages of the present in vention will be apparent from the following description, reference being had to the accompanying drawin s, wherein a preferred form of the embo iment of the present invention is clearly shown.

In the drawings:

Fig. 1 is a side elevation.

Fig. 2 is a sectional view of the device taken on the line 2 2 of Fig. 1.

Fig. 3 is a sectional view taken along th line 3 3 of Fig. 2.

Fig. 4 is a fragmentary sectional view similar to aportion of Fig. 3, showing the crimping die immediately after preforming the crimping operation.

Fig. 5 is a fragmentary View taken on the line 5 5 of lFig. 2, showing `the severing device.

Fig. 6 'is a sectional view of the intermittent rotating device taken on the line 6 6 of Fig. 2.

Fig. 7`is a detailview of a member of the dial.

Figs. 8 and 9 are detail views of a clamping bolt with an integral arcuate key.

Fig. 10 is a sectional view taken on the line 10 10 of Fig. 7. 1.Figs. 11 and 12 show the partially formed c 1p. j

Fig. 13 shows the assembled flexible lead.

Referring to the drawings, the reference character indicates the base of a press. Bolted to the base 20 is a tool supporting member or base 22. This tool supporting member 22 has mounted thereon a rotary dial mechanism 24by means of a stud 26 threadedly engaging the member 22. Mounted on the stud 26 isa rotary member 28, as best seen in Fig. 7 This rotary member 28 has a plurality of radially extending slots 30 and triangular projections 32, the purpose of which will appear later.

In each of the radially extending grooves 30 is mounted a forming or crimping die 34 pivotally attached by a pin 40 to a lug 36, which is secured to member 28 by a screw 38. Lug 36 fits snugly between two adjacent triangular projections so as to prevent rotation of member 36 about the screw 38.

In the lperiphery of member 28 is an annular groove 42 for supporting a cable. Die 34 has a similar, but larger groove 44 aligned with the groove 42 so that substantially a continuous groove extends around the dial. The groove 44 is made large enough to accommodate the clip in addition to the cable, as will appear more clearly later. Concentric with member 28 is mounted an l annular member 46 attached to the base 22 by suitable bolts 48. This annular member 46 has an inclined surface 50 having substantially the same slant as the inclined surfaces 52 and 53 of members 28 and 34, respectively.l Another annular member 54 having a plurality of shouldered recesses 56 is secure to member 28 by a plurality of bolts 58. This annular member 54 limits the rotation of dies v34 about pins 40.

A suitable means for intermittently rotating the dial 24 includes a reciprocating member 60 having adove-tailed groove into which fits the dove-tailed tongue 63 projecting from base 22. Mounted on member 60 by means of a stud 64 is an oscillating arm 62 and a spring 66 biasing arm 62 in a counter-clockwise-di- 100 w Support ber 22 by means of a bolt 122 having a square A rection as viewed in Fig. 2. On the arm 62 opposite the stud 64 is a pawl 68 which engages the shoulders 70 of the notches 56 in member 54. Y A suitable driving means for reciprocating member 60 com rises av lug 72 attached to member 60 by aV pair of studs 7 4. Lug 72 is connected to bell crank lever 84 by means of a connecting rod 76 comprising rods 78 and 80 lo each threadedly engaglng member 82, Whereby the length of the connecting rod 76 may be adjusted as clearly seen in' Figs. 1 and 2. The bell crank being pivotally mounted on tle upright 88 as best seen in Fig. 1, by means o a lurality of bolts 92. To the other endof the Bell crank lever 84 is pivotallyconnected by pin 94 to a itman 96 connected to a crank pin 98 mounte in a radial groove 100 in drivlng member or wheel 102 mounted upon a drive shaft 104. The eccentricity of pin -98 may be 'varied by adjusting it in the groove 100. Drive shaft 104 may be drivenby suitable means (not shown). It may be readily seen that as the wheel 102 is rotated through one revolution, oscillating motionwill be imparted to bell crank 84 which will reciprocate member 60. As member is actuated during the first half-revo- 33 lution of shaft 104, as viewed in Fig. 1, pawl 68 will be lretracted so as to be ready to engage a lsucceeding notch 56a in member 54, an as member 60 is actuated during the second half-revolution, pawl 68 will be advanced 35 to en ge this succeeding notch and rotate the d1al 24 'in a counterclockwise direction, as viewed in Fi 2, through a distance equal to the distance tween successive notches.

'It is necessary to apply a. braking force u upon the dial 24 in order *.to prevent a clockwise rotation of the dial 24. A leather wash- .e'r 106 is 'inserted intermediate member 28 and member 107. `Rotation of member 1 07 is prevented-by, a key 111 engaging a recess in a each of members 26, 106 and 107. From this it ma .readily be seen that by adjusting the nut 1 2 thedesired friction between members 108 and 28 may beobtained.

1s mounted on supporting mem- -head 124 and an .arcuateke 126 in al with the head 124andthe lt 122. e square head A124 v'ta into an arcuate groove fp. 128-insupporting member 22. Thearcuate key 126 prevents 4the sup rting member 130 from rotangabout the lt 122 for the reason that thisey 126 engagesthe sides of the groove 132. insupporting member 22 and it a. notherf-lt 136 threadedly engaging the support `22 and extending up through a slot i 1 88 in memberl() ooo rates with bolt 122 in' holding member 130 1n arigid-position on racket attached to member 88 'by a b device which includes a la groove 134in member 130;v

a clockwise or a counterclockwise direction with respect to the center of dial 24 so as to properly align a crimping die 140, with the die 34 mounted in groove 30.

The crimping die is mounted in a suitable recess 142 in member 130 and held in position by a plate 144 secured to member 130 by bolts 146. The crimping die 140 has a pin 148 ixedly attached thereto extending through a vslot 150 in member 144. Another 75 pin 152 is fixedly attached to member 144 so that a tension spring 154 tends to move the crimping tool away from the dial. The crimping die 140 is actuated toward the dial y means of a reciprocating wedge-shaped 30 member 156. This wedge-shaped member is guided in a recess 158 in member 130 a recess 164 in member 130 has been provided for a roller mounted on a pin 162 attached to member 130 in order to reduce the friction 85 between the wallof the recess 158 and member 156.

A severing device which includes a support 171, is mounted on supporting member 22. The support 171 is secured to the i0 base 22 by bolts 122a and 138a. The arcuate key 126a integral with the head 124a and bo1tf122a prevents rotation of the supporting member 171. .Member or support 171 may be adjusted in a clockwise or' a counter` 96 clockwise direction with respect to the center of the dial 24 so as to properly align the severing tool 172 with the edge of a groove 30 in member 28 so that the knife 172 enters the notch 174 in member 28 and a notch 176 100 in member 46.

The severing tool 17 2 is mountedin a suitable recess 177 in member 171, held in position by a plate 178 secured to member 171 by bolts 180. The severing tool 172 has a lol pin1182 fixedly attached thereto extending through a slot 184 in plate 178. Another in 186 -is xedly attached to plate 178 so at a tension spring 188, which has one end attached to pin 182 and the other end attached 110 to pin 186, tends to move the severing tool away from the dial. The severing tool 172 is actuated toward the dial by means of a reciprocating wedge-shaped member` 190 ex tending into the recess 192 in member 171. lli

moese 194 in member 171 has been provided for a roller 195 mounted on a pin 197 attached to member 171 in order to reduce the friction between the wall of the recess 192 and member 190. 190

The'actuating members 166l and 190 are driven by a suitable driving mechanism comprising a reciprocating crosshead 196 into which are fixed securely members 156 and 190. Bymeans of -a ball and socket joint' 198 125 or any other suitable method, a connecting rod 200 is connected to thecrosshead 196.' An eccentric cam 202 mounted on the shaft 144 actuatesmember 200 so that for each revolution of the shaft 104 the crimping die .N

140 and the knife 170 will be advanced toward the dial.

Operation Before starting the device a cable 210, which has a clip crimped uponv it near one end, is put into grooves 42 and 44 by the operator so that a crimped clip is in the operating station adjacent the knife. Partially formed clips 212 `having substantially the shape of a capital J are hooked on to the cable in the groove adjacent the crimping die 140 and one into each of a couple of preceding grooves as seen in Fig. After the cable, the crimped clip and the three partially formed clips have-been placed in this position, the device is ready for operation.

As the driving shaft 104 begins rotating from the position disclosed in Fig.r 1, members 156 and 190 will be forced downwardlv during the rst half revolution of the shaft 104. This will cause the crimping die to be begins to rotate.

moved toward the dial 24. whereby a groove 141 in the crimping die will engage the J- shaped clip 212 in the preassembled position, forcing-this clip around the cable to grip it, asbest seen in Fig. 4. At the same time knife 172 will move toward the dial so as to sever the cable adjacent a clip which has alreadv been crimped on to the cable.

As the dimensions of crank arm 84 Iand the distance of pin 98 from the center of shaft 104 has been so proportioned that pawl 68 moves a substantial distance past the succeeding groove 56. although not far enough to engagea second succeeding groove. shaft 104 is permitted to begin the second half of a revolution fromthe position in Fig. 1 so as to allow the crimping tool 140 and the knife 172 to be retarded bv the springs 154 und 188 to such a distance that the dial will clear the crimping tool andthe knife before it It will thus be seen that the dial will be rotated in a counterclockwise direction during less than the last half of the rst revolution. i

As the end of the cable 210 and the clip 212 is cut therefrom, the flexible lead and the clip 214 drops into an aperture or opening 209 in supporting member 22vand in the base 20. The annular member 46 has been cut away at 47 so that there will be nothing to support the clip 212 shortly after clip 212 has been rotated away from knife 172.

It will be noted that no specific method of pre-forming the clips into the specific shapedisclosed, has been described.l The manner in which these clips. are made is of no ,import-A ance so far as this inventionis concerned,

it being only essential that clips of substantially .the form claimed be used.

From this it may readily be seen that all the operator isv required to do'is to insert a partially formed clip 212 into each succeeding groove 30 during the rest period of the dial, at position A for example.

This will reduce the cost of production, as

the device will crimp the clip on to a cable and -it will cut the cable at the succeeding stage with the clip rigidly attached thereto, thereby speeding up production, reducing the time and reducing the labor so as to produce a cheaper and a better connector.

While the form of embodiment of the present invention as herein disclosed, constitutes a preferred form, it is to'be understood that other forms might be adopted, all coming within the scope of the claims which follow,

What is claimed is as follows:

1. A device for producing a flexible electrical'connector, comprising in combination, rotary means for intermittently feeding a cable; means for receiving a partially formed clip, said means holding the clip adjacent to the cable ;.means for crimping the clip to the cable; and means for Severin the cable adjacent the crimped "clip, there y forming an electrical connector having a clip attached thereto.

2. A device for producing a iexible electrical connector, comprising in combination,-

means for recelving and for holding a partially formed clip adjacent t-o a cable; reciprocating means for crimping the clip to the cable; means for severing the cable adjacent the crimped clip, and means for feeding the cable to each of said means in succession, whereby electrical 'connectors are formed periodically.

3. A device for producing flexible electrical connectors with a clip attached thereto, comprising in combination, means for inter'- mittently feeding a `cable to a' plurality of operating stations; means for crimping a clip to the cable at one of said operatin stations; and means for severing the cable a jacent the crimped clip at another operating station whereby electrical connectors are produced periodically.

4. A device for producing {iexible leads having clips attached thereto, comprising in combination, means intermittently operated for feeding a cable to a plurality of operating positions; means for holding a partially formed clip adjacent to the cable; reciprocating means for crimping the clip during a rest period of the cable feeding means; positive driving means for moving the reciprocating means toward the cable; land resihent means Vbiasing' the reciprocating means from the cable.-

5. -The process of producing a flexible eon-v nector comprising the steps of pre-assembling a partlally formed clip and a lead, moving the pre-assembled clip and lead to an operating position, crimping the clip at the operating position so as to attach the clip to the lead, moving the lead and the clip attached thereto to another operating position,

- of firming a J-shaped clip severing the cable adjacent to the clip at s aid other operating position whereby a iexlble lead with a clip attached thereto is produced.

6. The process of producing a exible con- 5 nector, comprising the steps of feeding a cable to a pre-assembling position; hooking a partially formed J-shaped clip to the cable at the pre-assembling position; feeding the clip and the cable to an operating position;

l0 `crimping the partially formed clip to the cable at said operating position, and feeding the crimped clip and the cable to another operating station, severing the cable adjacent the clip at said other operating station, thereby producing a flexible lead having a clip attached thereto.

7. The process of producing a flexible connector from a piece of sheet metal and a cable including the steps of forming the piece of sheet metal into a substantially J-shaped clip;

hooking the J-shaped clip on thecable; feeding the J-shaped clip and the cable in a preassembled relation to an operating station; crimping the clip, while at said operating station, so as to iix it to the cable; and severing the cable adjacent the clip whereby a ilexible connector is produced. Y

8. rThe process of producing a iexible lead with a clip attached thereto, from a iece of sheet metal and a cable comisin t e steps m t e piece of sheet metal; hooking the J-shaped cli on the cable; moving the J-shaped clip an .the cable in a'pre-assembledrelation to a crim ing station; crimping the clip to the cab e at the crimping station; moving the crimped clip and the cable to a Severin station; and' severing the cable adjacent t e clip at the` severing station so as to produce a flexible' y 4 lead with a clip attached thereto.

9. The process of roducing flexible leads haying clips attach thereto comprising the simultaneous steps of hooking a J-shaped clip on a cable; crimping another J-shaped 45 clip to the cable at an operating station; and

means for feeding a flexible wire, means for fastening a termmal clip to the wire, means for cutting of a iece of the wire with the clip attached, and) driving means for driving said clip fastening means and said cutting means, said drivmg means including a common reciprocating member for actuat-` ing the fastening and the cutting means.

12. An apparatus for making electrical connectors, comprising in combination, means for holdin a terminal clip against a wire, means for the clip, means for cutting the wire, an means for feeding the wire and the attached clip to the cutting means after the clip has been fastened to the 13. An apparatus for making electrical connectors, comprising in combination, means for receiving and holdin a terminal clip against the wire, means or fastening the clip, means for cutting the wire, and means for feeding the unattached clip to the fastening means, and for feeding the wire and the attached clip to the cutt' means.

14. An a paratus aoco to claim 13 in which the seeding means inc udes a member which engages an attached clip in order to feed the wire to each of said means.

In testimony whereto I hereto ax my signature.

' LORA E. POOLE.

severing the cable adjacent a crimped clip i at a succeeding o ration station, so as. to severvfrom the cab e a flexible lead having a clip attached thereto.

10. The process of producing flexible leads having clips attached thereto from a J-shaped clip and a continuous cable, comprising a series of cycles of steps, each cycle of steps including; the advancing of the cable with a partially formed J-shaped `clip hooked thereon and with a clip`previously crim thereto a distance ual to the len h of the flexible lead; then simultaneously ooking a J-shaped clip on the cable,

00 viously hooked-on J-shaped ch an e ing the cable adjacent a crimped cli l y a flexible lead with a clip crimpe thereto is produced per cycle of steps. Y

11. An apparatus for makingV an electri- Severwhere- 68 cal connector, comprising in'combination, 

